US11501898B2 - Wire harness and method of manufacturing wire harness - Google Patents

Wire harness and method of manufacturing wire harness Download PDF

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Publication number
US11501898B2
US11501898B2 US17/043,105 US201817043105A US11501898B2 US 11501898 B2 US11501898 B2 US 11501898B2 US 201817043105 A US201817043105 A US 201817043105A US 11501898 B2 US11501898 B2 US 11501898B2
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United States
Prior art keywords
electrical wire
insulating covering
covering
wire
sheet material
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US17/043,105
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US20210027916A1 (en
Inventor
Housei MIZUNO
Hiroki Hirai
Makoto Higashikozono
Daichi Fukushima
Miyu Aramaki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Wiring Systems Ltd
AutoNetworks Technologies Ltd
Sumitomo Electric Industries Ltd
Original Assignee
Sumitomo Wiring Systems Ltd
AutoNetworks Technologies Ltd
Sumitomo Electric Industries Ltd
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Application filed by Sumitomo Wiring Systems Ltd, AutoNetworks Technologies Ltd, Sumitomo Electric Industries Ltd filed Critical Sumitomo Wiring Systems Ltd
Assigned to AUTONETWORKS TECHNOLOGIES, LTD., SUMITOMO ELECTRIC INDUSTRIES, LTD., SUMITOMO WIRING SYSTEM, LTD. reassignment AUTONETWORKS TECHNOLOGIES, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ARAMAKI, Miyu, FUKUSHIMA, DAICHI, HIGASHIKOZONO, MAKOTO, HIRAI, HIROKI, MIZUNO, Housei
Publication of US20210027916A1 publication Critical patent/US20210027916A1/en
Assigned to AUTONETWORKS TECHNOLOGIES, LTD., SUMITOMO ELECTRIC INDUSTRIES, LTD., SUMITOMO WIRING SYSTEMS, LTD. reassignment AUTONETWORKS TECHNOLOGIES, LTD. CORRECTIVE ASSIGNMENT TO CORRECT THE SECOND ASSIGNEE NAME SHOULD READ SUMITOMO WIRING SYSTEMS, LTD.. PREVIOUSLY RECORDED AT REEL: 054232 FRAME: 0722. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Assignors: ARAMAKI, Miyu, FUKUSHIMA, DAICHI, HIGASHIKOZONO, MAKOTO, HIRAI, HIROKI, MIZUNO, Housei
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/40—Insulated conductors or cables characterised by their form with arrangements for facilitating mounting or securing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • H01B13/01209—Details
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/448—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from other vinyl compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/0207—Wire harnesses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/0045—Cable-harnesses

Definitions

  • the present invention relates to a technique of attaching electrical wires to an exterior member in a wire harness for vehicle.
  • Patent Document 1 discloses a technique, when a sheet-like exterior member is attached to electrical wires, for positioning the exterior member with respect to the electrical wires by winding a tape around each end portion of the exterior member and the electrical wires extending from the end portion.
  • Patent Document 1 Japanese Patent Application Laid-Open No. 2015-72798
  • the applicant of the present application proposes, as a new method of fixing the electrical wires and the sheet-like exterior member, a method of directly fixing an insulating covering of the electrical wires and a sheet material by welding.
  • a thickness of the wire harness is considered a sum of a diameter of the electrical wires and a thickness of the sheet material before welding, for example.
  • the wire harness is disposed in a limited space in a vehicle, so that if the thickness of the wire harness increases, a freedom degree of locating the wire harness may decrease.
  • an object of the present invention is to provide a technique capable of reducing a thickness of a wire harness in which an insulating covering of an electrical wire and a sheet material are directly welded and fixed.
  • a wire harness includes: an electrical wire including a core wire and an insulating covering for covering the core wire; and a sheet material in which the electrical wire is disposed on a resin main surface, and a part of the main surface having contact with the electrical wire is welded to the insulating covering of the electrical wire, thereby forming an electrical wire fixing part, wherein a thickness dimension of a first covering part in the insulating covering on a side of the electrical wire fixing part in relation to the core wire is formed smaller than a thickness dimension of a second covering part located on an opposite side of the core wire.
  • a wire harness according to a second aspect is the wire harness according to the first aspect, wherein a sum of a thickness dimension of a part of the sheet material to which the first covering part is welded and a thickness dimension of the first covering part is formed equal to or larger than a thickness dimension of the second covering part.
  • a wire harness according to a third aspect is the wire harness according to the first or second aspect, wherein a width dimension at a boundary surface of a welding part between the insulating covering and the sheet material is formed larger than a width dimension in a part of the electrical wire through a center of the core wire.
  • a wire harness according to a fourth aspect is the wire harness according to any one of the first to third aspects, wherein a part including the electrical wire fixing part is formed equal to or harder than the insulating covering.
  • a wire harness according to a fifth aspect is the wire harness according to the fourth aspect, wherein both the insulating covering and the electrical wire fixing part are formed of a material including polyvinyl chloride and a plasticizer, and a ratio of a plasticizer to polyvinyl chloride constituting the part including the electrical wire fixing part is equal to or smaller than a ratio of a plasticizer to polyvinyl chloride constituting the insulating covering, thus the part including the electrical wire fixing part is formed equal to or harder than the insulating covering.
  • a method of manufacturing a wire harness includes steps of: (a) locating an electrical wire including a core wire and an insulating covering for covering the core wire on a resin electrical wire disposed part in a sheet material, and sandwiching the electrical wire and the electrical wire disposed part by a sandwiching member; and (b) after the step of (a), ultrasonic-welding the insulating covering and the electrical wire disposed part, wherein at a time of performing the step of (b), a part including the electrical wire disposed part becomes equal to or harder than the insulating covering.
  • a method of manufacturing a wire harness according to a seventh aspect is the method of manufacturing the wire harness according to the sixth aspect, wherein both the insulating covering and the electrical wire disposed part are formed of a material including polyvinyl chloride and a plasticizer, and at a time of performing the step of (b), a ratio of a plasticizer to polyvinyl chloride constituting the part including the electrical wire disposed part is equal to or lower than a ratio of a plasticizer to polyvinyl chloride constituting the insulating covering, thus the part including the electrical wire disposed part becomes equal to or harder than the insulating covering.
  • the thickness of the wire harness can be reduced by the amount that the thickness dimension of the first covering part is made smaller than the thickness dimension of the second covering part. At this time, insulation properties of the first covering part having the reduced thickness can be compensated by the sheet material.
  • insulation properties on the side of the first covering part for the core wire can be increased.
  • adhesion strength in welding can be increased.
  • the thickness dimension of the first covering part can be made easily smaller than the thickness dimension of the second covering part.
  • the electrical wire fixing part can be formed harder than the insulating covering.
  • the sheet material is equal to or harder than the insulating covering under a temperature heated by frictional heat at the time of the ultrasonic welding and pressure, thus when the welding proceeds in that state, the part of the insulating covering on the side of the sheet material is deformed to the same degree or more easily than the sheet material.
  • the thickness of the part of the insulating covering on the side of the sheet material in relation to the core wire can be made smaller than that on the opposite side thereof.
  • the electrical wire fixing part can be formed equal to or harder than the insulating covering.
  • FIG. 1 A cross-sectional view illustrating a wire harness according to an embodiment.
  • FIG. 2 A drawing for explaining a thickness dimension of each part of the wire harness.
  • FIG. 3 A drawing for explaining a width dimension of each part of the wire harness.
  • FIG. 4 A diagram for explaining a manufacture of the wire harness according to the embodiment.
  • FIG. 5 A diagram for explaining a manufacture of the wire harness according to the embodiment.
  • FIG. 6 A cross-sectional view illustrating a wire harness according to a modification example.
  • FIG. 1 is a cross-sectional view illustrating a wire harness 10 according to the embodiment.
  • the wire harness 10 is used as a wiring member mounted to a vehicle to electrically connect various apparatuses, for example.
  • the wire harness 10 includes an electrical wire 20 and a sheet material 30 .
  • one electrical wire 20 is disposed on one sheet material 30 , and there may also be obviously a case where a plurality of electrical wires 20 are disposed on one sheet material 30 .
  • the electrical wire 20 is connected to various apparatuses mounted to a vehicle via a terminal or a connector connected to an end portion of the electrical wire 20 , for example.
  • the electrical wire 20 includes a core wire 22 and an insulating covering 26 for covering the core wire 22 .
  • the core wire 22 is made up of one or a plurality of strands 23 (seven in the example illustrated in FIG. 1 ).
  • Each strand 23 is a linear member formed of a conductive material such as copper, copper alloy, aluminum, and aluminum alloy, for example.
  • the core wire 22 is preferably a stranded wire made up of the plurality of strands 23 .
  • the insulating covering 26 is formed by extrusion molding of a resin material having insulation properties such as polyvinyl chloride (PVC) or polyethylene (PE) around the core wire 22 or applying a resin coating of enamel, for example, around the core wire 22 .
  • the insulating covering 26 includes a thermoplastic resin.
  • the insulating covering 26 is formed of a resin material including PVC.
  • the insulating covering 26 is formed of a material with PVC as a base to which a plasticizer is added.
  • the plasticizer is an additive agent for softening a synthetic resin product, and in the synthetic resin product a product having a high ratio of the plasticizer to the synthetic resin is generally softer than a product having a low ratio of the plasticizer.
  • a type of the plasticizer is not particularly limited, but applicable is a plasticizer such as phthalic ester, trimellitic acid ester, pyromellitic acid ester, fatty acid ester, and fatty acid polyester, for example.
  • One type of the plasticizer may be solely used, or plural types of the plasticizers may also be used together. It is also considered that various types of additive agents such as a stabilizer other than the plasticizer is added to PVC constituting the insulating covering 26 .
  • At least part of the insulating covering 26 disposed on the sheet material 30 is welded (herein, ultrasonic welded) to the sheet material 30 , thus the electrical wire 20 is fixed to the sheet material 30 .
  • a route of the electrical wire 20 disposed on the sheet material 30 is not particularly limited.
  • the electrical wire 20 may extend linearly on the sheet material 30 or may also be curved.
  • the plurality of electrical wires 20 are disposed on one sheet material 30 , there may be a case where the plurality of electrical wires 20 all extend in the same direction or partially extend in a different direction.
  • a branch part where the plurality of electrical wires 20 branch off is formed on the sheet material 30 .
  • region is welded in the electrical wire 20 disposed on the sheet material 30 along a longitudinal direction.
  • the insulating covering 26 and the sheet material 30 may be sequentially welded along the longitudinal direction of the electrical wire 20 , or a partial welding (spot welding) may be performed on a plurality of positions along the longitudinal direction of the electrical wire 20 .
  • spot welding spot welding
  • a whole region in the electrical wire 20 disposed on the sheet material 30 may be welded or there may be partially an area not welded.
  • a pitch between the spot welding positions may be or may not be constant.
  • An outer peripheral surface of a part of the insulating covering 26 welded to the sheet material 30 is formed into a shape partially deformed from a circumferential surface shape.
  • a so-call round wire having a uniform circumferential surface shape is adopted as the electrical wire 20 , and a part of the insulating covering 26 in the round wire is partially deformed to form the electrical wire 20 described above.
  • the sheet material 30 includes an electrical wire fixing layer 32 made of resin.
  • the sheet material 30 has a single layer structure of only the electrical wire fixing layer 32 .
  • the electrical wire 20 is disposed on a main surface 33 of the electrical wire fixing layer 32 made of resin.
  • a part of the main surface 33 having contact with the electrical wire 20 is welded to the insulating covering 26 of the electrical wire 20 , thereby forming an electrical wire fixing part 34 .
  • the part of the electrical wire fixing layer 32 other than the electrical wire fixing layer 34 that is to say, the part where the electrical wire 20 is not disposed on the main surface 33 is referred to as an electrical wire un-disposed part 36 .
  • a part of the sheet material 30 including the electrical wire fixing part 34 (the electrical wire fixing layer 32 herein) is formed equal to or harder than the insulating covering 26 . Rockwell hardness, for example, can be used as an index of such hardness.
  • a material constituting a part of the sheet material 30 including the electrical wire fixing part 34 is not particularly limited as long as it can be welded to the insulating covering 26 .
  • the part of the sheet material 30 including the electrical wire fixing part 34 preferably include the same resin as the insulating covering 26 . Accordingly, adhesion strength between the electrical wire fixing part 34 and the insulating covering 26 by welding can be increased.
  • the insulating covering 26 includes PVC, thus the part of the sheet material 30 including the electrical wire fixing part 34 is also formed of a material including PVC.
  • the part of the sheet material 30 including the electrical wire fixing part 34 is formed of a material with PVC as a base to which a plasticizer is added.
  • a type of the plasticizer is not particularly limited, but applicable is a plasticizer such as phthalic ester, trimellitic acid ester, pyromellitic acid ester, fatty acid ester, and fatty acid polyester, for example.
  • One type of the plasticizer may be solely used, or plural types of the plasticizers may also be used together.
  • a plasticizer added to PVC constituting the part including the electrical wire fixing part 34 is the same as a plasticizer added to PVC which is a material of the insulating covering 26 .
  • a ratio of the plasticizer to PVC constituting the part including the electrical wire fixing part 34 is equal to or lower than a ratio of the plasticizer to PVC constituting the insulating covering 26 , thus the part including the electrical wire fixing part 34 is equal to or harder than the insulating covering 26 .
  • plasticizer added to PVC constituting the part including the electrical wire fixing part 34 is different from the plasticizer added to PVC constituting the insulating covering 26 . It is also considered that various types of additive agents such as a stabilizer other than the plasticizer is added to PVC constituting the part including the electrical wire fixing part 34 .
  • the sheet material 30 and the insulating covering 26 are welded while the insulating covering 26 is deformed to follow the main surface 33 of the sheet material 30 .
  • a boundary surface of the welding to the electrical wire fixing part 34 is formed into a shape closer to the shape of the main surface 33 in the electrical wire un-disposed part 36 than the circumferential surface shape of the insulating covering 26 .
  • the above deformation in the insulating covering 26 occurs in ultrasonic welding. That is to say, the round wire and the sheet material 30 are ultrasonic-welded, thus the part of the insulating covering 26 ultrasonic-welded to the sheet material 30 is deformed from the original circumferential surface shape to a shape following the main surface 33 of the sheet material 30 (herein, a shape close to a flat surface). In this manner, it is considered that the insulating covering 26 is deformed in the ultrasonic welding by reason that the sheet material 30 is equal to or harder than the insulating covering 26 as described above, thus a deformation amount of the insulating covering 26 is larger than that of the sheet material 30 in the ultrasonic welding.
  • FIG. 2 is a drawing for explaining a thickness dimension of each part of the wire harness 10 .
  • a hatching of across section is omitted in FIG. 2 .
  • a dimension A in FIG. 2 is a thickness dimension of a first covering part 27 a in the insulating covering 26 located on a side of the electrical wire fixing part 34 in relation to the core wire 22 .
  • the dimension A is the thickness dimension in a direction through a center of the core wire 22 along a normal direction of the main surface 33 of the sheet material 30 , for example.
  • a position of the dimension A is located in a part where the electrical wire 20 and the sheet material 30 have first contact with each other at the time of the ultrasonic welding, for example.
  • a dimension B in FIG. 2 is a thickness dimension of a second covering part 27 b in the insulating covering 26 located on an opposite side of the core wire 22 from the first covering part 27 a .
  • the dimension B is the thickness dimension in the same direction as the dimension A, for example.
  • a dimension C in FIG. 2 is a thickness dimension of a part of the sheet material 30 where the first covering part 27 a is welded.
  • the dimension C is the thickness dimension in the same direction as the dimension A, for example.
  • a dimension D in FIG. 2 is a thickness dimension in a position in the sheet material 30 apart from the electrical wire 20 .
  • the dimension D is considered a dimension of a part including the electrical wire un-disposed part 36 having the largest thickness.
  • the dimension D is considered to be the same as the thickness dimension of the sheet material 30 before welding.
  • the thickness dimension A of the first covering part 27 a in the insulating covering 26 on the side of the electrical wire fixing part 34 in relation to the core wire 22 is formed smaller than the thickness dimension B of the second covering part 27 b located on the opposite side thereof. Accordingly, a thickness dimension as the wire harness 10 is reduced.
  • the dimension C is formed smaller than the dimension D, however, there may also be a case where the dimension C is formed equal to or larger than the dimension D.
  • FIG. 3 is a drawing for explaining a width dimension of each part of the wire harness 10 .
  • a hatching of a cross section is omitted in FIG. 3 .
  • the width dimension herein indicates a dimension in a direction along a direction in which the main surface 33 of the sheet material 30 extends, and indicates a dimension in a direction along a direction intersecting (direction perpendicular to) a pressure direction in welding.
  • a dimension E in FIG. 3 is a width dimension at a boundary surface of a welding part between the insulating covering 26 and the sheet material 30 .
  • the dimension E is a dimension from one end portion to the other end portion at the boundary surface of the welding part between the insulating covering 26 and the sheet material 30 .
  • a dimension F in FIG. 3 is a width dimension in a part of the electrical wire 20 through a center of the core wire 22 .
  • the dimension F coincides with a diameter of the electrical wire 20 before welding, for example.
  • the width dimension E at the boundary surface of the welding part between the insulating covering 26 and the sheet material 30 is formed larger than the width dimension F in the part of the electrical wire 20 through the center of the core wire 22 . Accordingly, an area of the welding increases, and the bonding strength between the insulating covering 26 and the sheet material 30 can be increased.
  • FIG. 4 and FIG. 5 are diagrams for explaining a manufacture of the wire harness 10 according to the embodiment.
  • An electrical wire 20 B for example, in FIG. 4 and FIG. 5 illustrates the electrical wire before welding. That is to say, in the description hereinafter, when the electrical wire, the sheet material, and each element thereof before welding need to be distinguished from those after welding, a reference sign B may be added to the constituent elements before welding in some cases.
  • the electrical wire 20 B and a sheet material 30 B are ultrasonic-welded by an ultrasonic welding machine 80 to manufacture the wire harness 10 .
  • the electrical wire 20 B is around wire.
  • the sheet material 30 B is a member made up of one layer, and an electrical wire disposed part 34 B where the electrical wire 20 B is disposed has a flat surface.
  • the ultrasonic welding machine 80 includes a horn 82 and an anvil 84 .
  • the horn 82 is a member providing a work having contact with the horn 82 of ultrasonic vibration. It is also considered that a convex-concave shape is applied on a surface of the horn 82 having contact with the work as knurled processing, that is to say, for a purpose of slip resistance.
  • the anvil 84 is a member supporting the work with the horn 82 from an opposite side thereof. Accordingly, a pair of parts to be welded in the work are sandwiched between the horn 82 and the anvil 84 , thereby being provided with the ultrasonic vibration and welded.
  • the electrical wire 20 B is firstly disposed on an electrical wire disposed part 34 B formed equal to or harder than the insulating covering 26 B in the resin sheet material 30 B, and the electrical wire 20 B and the electrical wire disposed part 34 B are sandwiched by a sandwiching member.
  • the electrical wire 20 B before welding is disposed on a predetermined position on the main surface 33 of the sheet material 30 B (the electrical wire disposed part 34 B), and is supported by the anvil 84 .
  • the horn 82 is brought close to the anvil 84 , and the electrical wire 20 B and the sheet material 30 B are sandwiched by the horn 82 and the anvil 84 so that the insulating covering 26 B and the electrical wire disposed part 34 B have contact with each other.
  • the horn 82 is disposed to press a side of the sheet material 30 B
  • the anvil 84 is disposed to press a side of the electrical wire 20 B herein, however, also considered is a case where the horn presses the side of the electrical wire 20 B and the anvil presses the side of the sheet material 30 B.
  • a holding groove 85 holding the electrical wire 20 B is formed in a surface of the anvil 84 facing a side of the horn 82 .
  • a bottom surface of the holding groove 85 may have a flat surface shape or curved surface shape. In the example illustrated in FIG. 4 , the bottom part of the holding groove 85 is formed into the curved surface shape.
  • a depth dimension of the holding groove 85 is set to approximately equal to the diameter of the electrical wire 20 B (slightly smaller than the diameter of the electrical wire 20 B in the example illustrated in FIG. 4 ), thus a tip end portion of a wall part 86 constituting the holding groove 85 functions as a pressing part 89 sandwiching a part of the sheet material 30 B where the electrical wire 20 B is not disposed with the horn 82 .
  • a side closer to an opening part in relation to the bottom part of the holding groove 85 formed into the curved surface shape has a constant width.
  • an inner surface of the wall part 86 extending from the bottom part of the holding groove 85 to a tip end portion of the pressing part 89 constitutes a vertical surface 87 .
  • the wire harness 10 preferably has a small thickness.
  • the sheet material 30 B preferably has a small thickness.
  • a thickness dimension of the sheet material 30 B before welding is set smaller than the diameter of the electrical wire 20 B.
  • the thickness dimension of the sheet material 30 B before welding may be obviously set equal to or larger than the diameter of the electrical wire 20 B.
  • the thickness dimension of the sheet material 30 B before welding is set smaller than a radius of the electrical wire 20 B.
  • the thickness dimension of the sheet material 30 B before welding may be obviously set equal to or larger than the radius of the electrical wire 20 B.
  • the thickness dimension of the sheet material 30 B before welding is set larger than a thickness dimension of the insulating covering 26 B (herein, an average thickness dimension in view of a fact that the plurality of strands 23 are located).
  • the thickness dimension of the sheet material 30 B before welding may be obviously set equal to or smaller than the thickness dimension of the insulating covering 26 B.
  • the electrical wire 20 B and the electrical wire disposed part 34 B are sandwiched by the sandwiching member, and the insulating covering 26 B and the electrical wire disposed part 34 B are ultrasonic-welded to each other.
  • the ultrasonic vibration is provided by the horn 82 in a state where the part where the insulating covering 26 B and the sheet material 30 have contact with each other is sandwiched between the horn 82 and the anvil 84 .
  • the horn 82 presses the side of the sheet material 30 B, thus the ultrasonic vibration is provided from the side of the sheet material 30 B.
  • Frictional heat caused by the ultrasonic vibration is generated in the part where the insulating covering 26 B and the sheet material 30 have contact with each other, and at least one of them is melted, thus they are joined to each other.
  • both the insulating covering 26 B and the sheet material 30 B are formed of materials including PVC as a base, thus they are melted and joined to each other.
  • both the insulating covering 26 B and the electrical wire disposed part 34 B are formed of materials including PVC and a plasticizer.
  • the ratio of the plasticizer to PVC constituting the part including the electrical wire disposed part 34 B is equal to or lower than the ratio of the plasticizer to PVC constituting the insulating covering 26 B. This state is also continued at the time of the ultrasonic welding, thus the part including the electrical wire disposed part 34 B is equal to or harder than the insulating covering 26 B at the time of the ultrasonic welding.
  • the part including the electrical wire disposed part 34 B is equal to or harder than the insulating covering 26 B, thus force caused by pressure applied by the horn 82 and the anvil 84 tends to act as force of deforming the insulating covering 26 B in the part where the electrical wire disposed part 34 B and the insulating covering 26 B have contact with each other. Accordingly, a boundary surface between the electrical wire fixing part 34 and the insulating covering 26 B formed by welding the electrical wire disposed part 34 B is formed into a shape closer to shape of the main surface 33 in the electrical wire disposed part 34 B before welding than the circumferential surface shape which is the original outer peripheral surface of the insulating covering 26 .
  • the shape of the circumferential surface which is the original outer peripheral surface of the insulating covering 26 can be confirmed by the part.
  • the shape is hardly deformed at the time of welding in a surface on a side opposite to a surface to be welded, thus the shape of the circumferential surface can be also confirmed by this surface.
  • a gap S is provided on a lateral side of the contact part between the electrical wire 20 and the sheet material 30 B.
  • the insulating covering 26 softened in welding flows into the gap S.
  • the gap S is filled with a modification part 28 of the insulating covering 26 .
  • the inner surface of the holding groove 85 of the anvil 84 is located to fill an outer side of the gap S.
  • the insulating covering 26 softened in welding is dammed by the inner surface of the holding groove 85 of the anvil 84 , thus an outer surface of the modification part 28 of the insulating covering 26 is formed into a shape following the inner surface of the holding groove 85 of the anvil 84 .
  • the inner surface of the holding groove 85 of the anvil 84 is the vertical surface 87
  • the outer surface of the modification part 28 is a vertical surface 28 a corresponding to the vertical surface 87 .
  • an interface 29 occurs between the modification part 28 and the original insulating covering 26 in a part of the modification part 28 away from the sheet material 30 (a part on a side of the second covering part 27 b ).
  • the interface 29 is considered to occur when the original part of the insulating covering 26 falls short of melting by reason that energy on the modification part 28 is small at the time of the ultrasonic welding, for example.
  • the interface 29 is not formed when the original part of the insulating covering 26 melts by reason that energy on the modification part 28 is large at the time of the ultrasonic welding, for example.
  • the thickness of the wire harness 10 can be reduced by the amount that the thickness dimension A of the first covering part 27 a is made smaller than the thickness dimension B of the second covering part 27 b . At this time, insulation properties of the first covering part 27 a having the reduced thickness can be compensated by the sheet material 30 .
  • the width dimension E at the boundary surface of the welding part between the insulating covering 26 and the sheet material 30 is formed larger than the width dimension F in the part of the electrical wire 20 through the core wire 22 , thus the bonding strength of welding can be increased.
  • the part including the electrical wire fixing part 34 is equal to or harder than the insulating covering 26 , thus the thickness dimension of the first covering part 27 a can be made smaller than that of the second covering part 27 b.
  • the electrical wire disposed part 34 B and the electrical wire fixing part 34 can be formed harder than the insulating covering 26 by adjusting the ratio of the plasticizer.
  • the softness of the sheet material 30 and the insulating covering 26 is adjusted using the plasticizer. It is known that a plasticizer is transferred to a member having contact with the plasticizer as time proceeds, for example, in some cases. Thus, after the ultrasonic welding, the plasticizer may be transferred between the electrical wire fixing part 34 and the insulating covering 26 in some cases. In this case, it is also considered that immediately after welding, even when the electrical wire fixing part 34 is harder than the insulating covering 26 , the plasticizer of the electrical wire fixing part 34 and the plasticizer of the insulating covering 26 reach equilibrium, and the electrical wire fixing part 34 and the insulating covering 26 have the same hardness.
  • the insulating covering 26 is made harder than the electrical wire fixing part 34 by processing after the ultrasonic welding (for example, only the electrical wire fixing part 34 is hot-pressed in the electrical wire 20 and the electrical wire fixing part 34 ). Even in such a case, the boundary surface between the electrical wire fixing part 34 and the insulating covering 26 is considered to keep the shape following the main surface 33 .
  • the sheet material 30 is equal to or harder than the insulating covering 26 under a temperature heated by frictional heat at the time of the ultrasonic welding and pressure, thus when the welding proceeds in that state, the part of the insulating covering 26 on the side of the sheet material 30 is deformed to the same degree or more easily than the sheet material 30 .
  • the thickness of the part of the insulating covering 26 on the side of the sheet material 30 in relation to the core wire 22 can be made smaller than that on the opposite side thereof.
  • FIG. 6 is a cross-sectional view illustrating a wire harness 110 according to a modification example.
  • the sheet material 30 has a single layer structure, however, this configuration is not necessary. There may also be a case where a sheet material has two or more layers as is a case in a sheet material 130 in a wire harness 110 according to a modification example.
  • the sheet material 130 includes a first layer 32 as the electrical wire fixing layer 32 described above and a second layer 40 stacked on the first layer 32 .
  • the first layer 32 is uniformly formed of the same material as that constituting the part including the electrical wire fixing part 34 . Accordingly, the first layer 32 is formed of a material with PVC as a base to which a plasticizer, which is the same as that added to the insulating covering 26 , is added.
  • a ratio of the plasticizer to PVC constituting the first layer 32 is equal to or higher than a ratio of the plasticizer to PVC constituting the insulating covering 26 , thus the first layer 32 is formed equal to or harder than the insulating covering 26 .
  • the second layer 40 has physical properties different from the first layer 32 . More specifically, the first layer 32 is a part having physical properties more appropriate for welding to the insulating covering 26 than the second layer 40 , and the second layer 40 is a part having physical properties needed depending on usage of the sheet material 30 , for example.
  • the second layer 40 is considered to be formed harder than the first layer 32 for a purpose of improving shape retainability. Accordingly, handleability of the wire harness 10 at a time of assembling the wire harness 10 to a vehicle can be improved compared with a case where a sheet material 30 is made up only of the first layer 32 .
  • the second layer 40 is also considered to be formed harder than the first layer 32 for a purpose of improving abrasion resistance properties, for example.
  • the second layer 40 is considered to be formed harder than the first layer 32 by a material including the same resin as the first layer 32 as abase.
  • the first layer 32 includes PVC as the base, thus the second layer 40 is considered to include PVC as the base.
  • a ratio of the plasticizer to PVC constituting the second layer 40 is made lower than a ratio of the plasticizer to PVC constituting the first layer 32 , thus the second layer 40 can be harder than the first layer 32 .
  • the second layer 40 is also considered to be formed harder than the first layer 32 by a material including a resin different from the first layer 32 as a base.
  • the first layer 32 includes PVC as a base, thus the second layer 40 is considered to be formed of a material including a resin other than PVC such as PE, polyethylene (PE), polyethylene terephthalate (PET), for example, as a base.
  • PE polyethylene
  • PET polyethylene terephthalate
  • a method of forming the sheet material 30 having the first layer 32 and the second layer 40 is not particularly limited, however, it is considered that the sheet material 30 is formed by a coextrusion method of achieving a laminated structure with a single extrusion process or a laminating method of separately forming the first layer 32 and the second layer 40 into a sheet-like shape and then mutually attaching them.
  • the sheet material 130 is configured to have shielding properties and increase heat radiation properties.
  • a non-woven fabric or a foam resin sheet softer than the first layer 32 is adopted as the second layer 40 , thus the sheet material 130 is configured to increase a sound insulating function.
  • the sheet material is also considered to have a configuration of three or more layers. That is to say, a third layer and a fourth layer are sequentially stacked on the second layer 40 on a side opposite to the first layer 32 .
  • the insulating covering 26 is deformed from the circumferential surface shape to the shape close to that of the main surface 33 of the sheet material 30 at the time of the ultrasonic welding, however, this configuration is not necessary.
  • the insulating covering 26 may be previously deformed from the circumferential surface shape to the shape close to that of the main surface 33 of the sheet material 30 before the ultrasonic welding.
  • a part of the circumferential surface shape may be extrusion-molded into a flat shape at the time of the extrusion molding of the insulating covering 26 .
  • the sheet material 30 may be formed softer than the insulating covering 26 .
  • the sum of the thickness dimension C of the part of the sheet material 30 to which the first covering part 27 a is welded and the thickness dimension A of the first covering part 27 a is formed equal to or larger than the thickness dimension B of the second covering part 27 h , however, this configuration is not necessary.
  • insulation properties of the sheet material 30 are preferably higher than those of the insulating covering 26 . That is to say, the sum of the thickness dimension C and the thickness dimension A may be smaller than the thickness dimension B as long as the part of the thickness dimensions C and A has insulation properties equivalent to or higher than the second covering part 27 b.
  • the width dimension E at the boundary surface of the welding part between the insulating covering 26 and the sheet material 30 is formed larger than the width dimension F in the part of the electrical wire 20 through the core wire 22 , however, this configuration is not necessary. It is also considered that the width dimension E at the boundary surface of the welding part between the insulating covering 26 and the sheet material 30 is equal to or smaller than the width dimension F in the part of the electrical wire 20 through the core wire 22 .
  • the area of the welding part can be made small by reducing pressure at a time of ultrasonic welding or reducing vibration energy to be provided.
  • the electrical wire 20 is a round wire, however, this configuration is not necessary. There may also be a case where an electrical wire such as an angular wire, for example, other than the round wire is adopted as the electrical wire 20 .
  • the insulating covering 26 and the electrical wire fixing layer 32 are formed of a material including PVC as a base, however, this configuration is not necessary.
  • the insulating covering 26 and the electrical wire fixing layer 32 are formed of a material including PE or PP as a base.
  • a density of PE or PP which is to be a base of the insulating covering 26 is made equal to or lower than that of PE or PP which is to be a base of the electrical wire fixing layer 32 , or PE or PP which is to be a base of the insulating covering 26 is reacted with isobutylene, for example, thus the electrical wire fixing layer 32 can be made equal to or harder than the insulating covering 26 .
  • the outer surface of the modification part 28 has a shape following the inner surface of the anvil 84 , however, this configuration is not necessary.
  • the outer surface of the modification part 28 may not have a shape following the inner surface of the anvil 84 .
  • the modification 28 easily extends along the main surface 33 of the sheet material 30 , and as a result, the dimension E described above is considered to be larger than that illustrated in FIG. 3 .

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Details Of Indoor Wiring (AREA)
  • Insulated Conductors (AREA)
US17/043,105 2018-03-30 2018-08-22 Wire harness and method of manufacturing wire harness Active US11501898B2 (en)

Applications Claiming Priority (4)

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JPJP2018-067192 2018-03-30
JP2018-067192 2018-03-30
JP2018067192A JP6665882B2 (ja) 2018-03-30 2018-03-30 ワイヤーハーネス及びワイヤーハーネスの製造方法
PCT/JP2018/030915 WO2019187196A1 (ja) 2018-03-30 2018-08-22 ワイヤーハーネス及びワイヤーハーネスの製造方法

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US10639737B1 (en) * 2018-10-19 2020-05-05 Aptiv Technologies Limited Welding system and method
WO2022158391A1 (ja) * 2021-01-20 2022-07-28 古河電気工業株式会社 接合構造体およびその製造方法、ならびに電線用外装体

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US20210027916A1 (en) 2021-01-28
DE112018007407T5 (de) 2020-12-10
CN111902886A (zh) 2020-11-06
CN111902886B (zh) 2022-05-03
JP2019179630A (ja) 2019-10-17
JP6665882B2 (ja) 2020-03-13
WO2019187196A1 (ja) 2019-10-03

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